Process for producing same



Patented June 20, 1939 PATENT OFFICE ASPHALTIC ROCK COMPOSITION AND PROCESS FOR PRODUCINGSAME Garde James Hines, Kansas City, Mo. 7

No Drawing. Application May 28, 1935, Serial No. 23,949

11 Claims.

This invention relates to an asphaltic sand rock composition and a process for producing same, and more particularly to a composition of this character resulting from the subjection of pulverized sand rock, naturally impregnated with asphalt and artificially impregnated with pure asphalt, sulphur, sulphide of iron, and calcium carbonate, to a high degree of heat. I

The principal object of the present invention m is to provide an improved basic asphaltic sand rock composition derived from natural asphaltic sand rock deposits which, as a result of my process is susceptibleof production in varying consistencies especially designed for use as materials 15 for paving; flooring; pipe, cable and Wall coat- "ings; roofing; conduits; burial vaults; battery boxes; paint; and many other purposes.

Further objects of the invention are to provide an asphaltic sand rock composition of this character which, in all its consistencies, is tough, elas-' tie and moisture-proof; to provide a composition which is resistant to corrosion; to provide a composition which is resilient and thereby absorbs I calcium carbonate (021.003) to produce said com-- position.

rock extracted from natural deposits preferably containing approximately 12 to 14 percent by weight of asphalt, the asphaltic sand being pulverized in any suitable manner preferably to' a fineness capable of passing an approximately 40 to 60 mesh screen and thereafter placed with varying amounts of asphalt and. substantially constant amounts of sulphur, sulphide of "iron, and calcium carbonate in a suitable container preferably similar to that disclosed in Patent No. 1,986,871, issued January 8, 1935, to J. A. Withee, and myself as assignee, for Means for treating asphalt. The amount of the pure asphalt added to the pulverized asphaltic sand rock will necessarily vary depending upon the use to which the composition is to be put, but the basic composition remains the same.

For example, in using my process to produce a 55 composition suitable for a paving material; I'have In carrying out my process, I useasphaltic sand (Cl. 106-31) ,l

found that approximately 12 to 14 percent asphalt is sufficient to meet the requirements of a good roadway and pure asphalt need not be added provided, of course, that 12 to 14 percent asphalt is present in the asphaltic sand rock deposit. Sulphur is added to the asphaltic sand rock in an amount equal to approximately from 3 to 10 percent by Weight of the asphaltic sand rock. Sulphide of iron is added to the asphaltic sand rock and sulphur in an amount equal to approximately from 2 to '7 percent by weight of the asphalt sand. Calcium carbonate is added'to the asphaltic sand rock, sulphur, and sulphide of iron in an amount equal to approximately to 1%; percent by Weight of the sand, and the balance of the mixture to make 100 percent'consists of the sand rock exclusive of its asphalt content.

It may here be noted that as a source of sulphur, should the asphaltic content of the asphaltic sand rock bebelow 12 to 14 percent, I prefer to use a low grade asphalt base petroleum oil containing approximately from 1 to 5 percent sulphur to build up the asphalt content, for the reason that better results in the final product are obtained from the use of a naturally blended sulphur and asphalt bearing petroleum oil, further for the reason that my process provides'an outlet for such a low grade petroleum oil in its natural state, and further, for the reason that as the mix is heated, as later pointed out, byproducts of the petroleum oil ranging from naphtha to the heavier lubricating oils together with the volatile components of the mixture, may be drawn from the container and utilized as desired.

The sulphide of iron and calciumcarbonate are added in any suitable form.

After mixing the above named materials, the mixture is applied to the inlet of the container and heat is thereupon applied to the exterior of the container at a point which effects a temperature Within the container of approximately250 F. at its inlet opening and from approximately 700? F, to 1000 F. at its outlet opening, the mixture being agitated simultaneously with heating by suitable paddles especially adapted for continuously advancing the mixture from the inlet end of the container to its progressively greater heated outlet end. v

During its passage throughout the heat treated container, the mixture consisting of asphaltic sand rock, asphalt, sulphur, sulphide of iron and calcium carbonate loses individual characteristics and blends or vulcanizes into my improved composition and while I am not certain of the exact chemical reactions taking place during such vulcanization, from the experiments conducted with and results accomplished by my process and composition, I am led to believe that the sulphur present in the mixture combines with the unsaturated compounds contained in the asphalt or formed during the heat treatment, the resulting compounds enabling the mixture to withstand a degree of heat up to 1000 F. without decomposing. It also appears that the sulphide of iron serves as a catalyst in the reaction in which bitumen is con-- verted into unsaturated compounds suitable for combination with the sulphur as above described; In any event, the sulphide of iron gives toughness to the final product not otherwise attainable. It also appears that carcium carbonate added to the mixture in the manner described gives to the final product a binding quality superior to those heretofore used.

The final product emerges from the outlet of the container in the form of a rubbery matrix which may, by suitable means he granulated or blocked to facilitate storage or transportation, or merely be stored in its semi-liquid state in suitable containers.

An asphaltic sand rock deposit containing 12 to 14 percent by weight of asphalt does not always occur naturally and in such a case, when for example the percentage of asphalt is low e. g., 6 to 8 percent, more or less, it is necessary to sup ply this deficiency by adding either pure asphalt to the mixture, or preferably the asphalt contained with the sulphur in the above described low grade asphalt base petroleum oil. In this case, however, I have found it preferable to apply the pulverized asphaltic sand rock alone to the container and move it as described under heat progressing from 250 F. at theinlet to approxi mately 500 F. substantially midway the length of travel of the composition in the container, at which point the remaining ingredients above described are added and the mixture advanced under agitation and increasing heat to the outlet of the container.

While I have described my process as producing a composition suitable for paving material, it is also capable of producing what appears to be the same composition in different consistencies to en able utilization of such compositions for a Wide range of purposes, the particular difference in the final products residing in the variable amounts of asphalt contained in the mixture, while the amounts of sulphur, sulphide of iron, and calcium carbonate remains substantially the same.

For example, when I desire to use my process to produce a. composition suitable for burial vaults or battery boxes, relatively larger amounts of asphalt are necessary, i. e., from approximately 15 to percent in proportion to the weight of the asphaltic sand rock, this additional asphalt being added of course at an advanced point in the container as above described and the source preferably being an excess of the low grade asphalt base petroleum oil.

When using my composition for pipe coating materials and similar purposes, for example, I have found that approximately a 20 to 30 percent asphalt content in proportion to the weight of the asphaltic sand rock is preferable.

In other materials requiring liquid and semiliquid consistencies, for example as in paints and the like, it is necessary to increase the asphalt content of the mixture to approximately 60 percent or more, for example 80 percent, this being readily effected in the manner above described.

In all consistencies of my composition, I have found that toughness, elasticity, adhesiveness and resistance to the elements, as Well as acids, is present in a marked degree.

It is, therefore, apparent that I haxe provided a basic asphaltic sand rock composition susceptible to production in various consistencies and adaptable to a wide variety of uses.

What I claim and desire to secure by Letters Patent is:

l. The process for producing an asphaltic sand rock composition of the character described consisting in the steps of pulverizng asphaltic sand rock containing approximately 12 to 14 percent asphalt to a fineness capable of passing a 40 to mesh screen; mixing with said pulverized asphaltic sand rock, sulphur, sulphide of iron and calcium carbonate in a suitable container in amounts equal to approximately 3 to 10 percent, 2 to '7 percent and to 1 percent respectively in proportion to the weight of said asphaltic sand rock; agitating said mixture; and simultaneously advancing said agitated mixture through said containerv while subjected to heat progressively increased from approximately 250 F. at the entrance of said container to approximately 1000 F. at. the exit of said container, and drawing ofi volatile components of said mixture during advancement of the heated mixture.

2. The process for producing an asphaltic sand rock composition of the character described consisting in the steps of pulverizing asphaltic sand rock; mixing with said pulverized asphaltic sand rock, asphalt, sulphur, sulphide of iron and calcium carbonate in a suitable container in amounts equal to approximately 20 to 30 percent, 3 to liT'" percent, 2 /2 to 7 percent and to 1 percent respectivelyin proportion to the weight of said asphaltic sand rock; agitating said mixture; and

simultaneously advancing said agitated mixture midway the length of travel of the rock in the container; adding to the pulverized rock, asphalt and sulphur in the form of low grade asphalt base petroleum oil having a sulphur content of approximately 1 to 5 percent by weight of the oil to bring the asphaltic content of the asphaltic sand rock to approximately 12 to 14 percent and the sulphur to approximately 3 to 10 percent by weight of the asphaltic sand rock, sulphide or iron and calcium carbonate in amounts equal to approximately2 ,to 7. percent and' /z to 1 percent respectively in proportion to the weight or" said asphaltic sand rock; and continuing the agitation and advancement of said mixture through said container while subjected to heat progressively increased from approximately 500 F. to 1000 F. between said midway point and exit of said container.

4. The process for producing an asphaltic sand rockcomposition of the character described including pulverizing asphaltic sand rock containing approximately 6 to 8 percent asphalt to a fineness capable of passing a 40 to 60 mesh screen; applying said pulverized asphaltic sand rock to a suitable container; agitating said pulverized rock; simultaneously advancing said rock in said container while subjected to heat progressively increased from approximately 250 F. to 500 F. along the length of the container to a point substantially midway the length of travel of the rock in the container; adding to the pulverized rock, asphalt to bring the asphaltic content of the asphaltic sand rock to approximately 12 to 14 percent by Weight of the asphaltic sand rock, sulphur, sulphide of iron and calcium carbonate in amounts equal to approximately 3 to percent, 2 to 7 percent and to 1 percent respectively in proportion to the weight of said asphaltic sand rock; and continuing the agitation and advancement of said mixture through said container while subjected to heat progressively increased from approximately 500 F. to

1000 F. between said midway point and exit of said container.

5. The process for producing an asphaltic sand rock composition of the character described consisting in the steps of 'pulverizing asphaltic sand rock; mixing with said pulverized asphaltic sand rock, asphalt, sulphur, sulphide of iron and calcium carbonate in a suitable container in amounts equal to approximately to percent, 3 to 10 percent, 2 to 7 percent and to 1%; percent respectively in proportion to the weight of said asphaltic sand rock; agitating said mixture; and simultaneously advancing said agi- "tated mixture through said container while subjected to heat progressively increased from approximately 250 F. temperature at the entrance of said container to approximately 1000 F. at the exit of said container.

6. A composition of the character described including asphaltic sand rock having a content of approximately 12 to 14 percent asphalt; sulphur approximately 3 to 10 percent by weight of the asphaltic sand r-ock; sulphide of iron, approximately 2 to '7 percent by Weight of the asphaltic sand rock; and calcium carbonate approximately to 1%; percent by weight of the asphaltic sand rock.

7. A composition of the character described including asphaltic sand rock; asphalt approximately 15 to 30 percent by weight of said asphaltic sand rock; sulphur approximately 3 to 10 percent by weight of the asphaltic sand rock; sulphide of iron, approximately 2 to 7 percent by weight of the asphaltic sand rock; and calcium carbonate approximately to 1%, percent by weight of the asphaltic sand rock.

8. The process for producing an asphaltic sand rock composition of the character described consisting in the steps of pulverizing asphaltic sand rock containing approximately 12 to14= percent asphalt; mixing with said pulverized asphaltic sand rock, sulphur, sulphide of iron and calcium carbonate in a suitable, container in amounts equal to approximately 3 to 10 percent, 2 to '7 percent, and to 1 percent, respectively, in proportion to the weight of said asphalt sand rock; agitating said mixture; and simultaneously advancing said agitated mixture through said container while subjected to heat progressively increased from approximately 250 F. temperature at the entrance of said container to approximately from 700 F. to 1000 F. at the exit of said container.

9. A process of the character described which comprises blending pulverized asphaltic sand rock having variable quantities of asphalt with substantially constant quantities of sulphur,'sulphide of iron, and calcium carbonate in proportions to the asphaltic sand rock of from approximately 3 to 10 percent S, 2 to 7 percent FeS and to 1% percent CaCOs by subjecting 0 said mass in a suitable container to agitation and increasing heat ranging between approximately from 250 F. to 500 F. and 700 F. to 1000 F.

10. A process of the character described which comprises blending pulverized asphaltic sand rock having variable quantities of asphalt with substantially constant quantities of sulphur, sulphide of iron, and calcium carbonate in proportions to the asphaltic sand rock of from approximately 3 to 10v percent S, 2 to 7 percent FeS and /2 to 1%, percent CaCOa by applying said asphaltic sand rock'to a suitable container; agitating and advancing said asphaltic sand rockin said container while subjected to increasing heat ranging between approximately from 250 F. at the inlet of said container to approximately 500 F. at a point substantially midway of said container; adding said other ingredients to said asphaltic sand rock; and continuing said agitation and advancement under increasing heat or: from approximately 700" F. to1000 F. at the exit of said container.

11. A composition'of the character described including a blended mass of pulverized asphaltic sand rock having variable quantities of asphalt and substantially constant quantities of sulphur, sulphide of iron and calcium carbonate in proportions to the weight of the asphaltic sand rock of from approximately 3 to 10 percent S, 2 to '7 percent FeS and V to 1%, percent CaCOa.

GARDE JAMES I-IINES. 

